Cage nut with non-cross threading angled cage

ABSTRACT

A cage nut assembly is disclosed having a body defining a through bore. The cage is disposed about at least a portion of the body. The body is hexagonal in shape, while the cage defines a seam configured to be placed adjacent the coupling surface of the cage and base material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 10/818,442 filed on Apr. 5, 2004. The disclosure of the aboveapplication is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to an encaged threaded fastener, and, moreparticularly, to an encaged fastener which minimizes problems of cagedeformation caused by miss-insertion of a threaded member into thefastener.

BACKGROUND OF THE INVENTION

With ever increasing design demands, flexibility and adaptivity ofunibody construction is increasingly required in order to providevehicles that meet broader customer needs. Increases in the number ofcomponents and structures which are coupled to the unibody constructionhave led designers to consistently add threaded fasteners to the unibodyframe. Variation in manufacturing tolerances require that the fastenercouple to the unibody frame in a way which allows a degree of positionaladjustment during final assembly. This positional adjustment is providedby using a female fastener which is an encaged fastener. Typically, thistakes the form of a nut encaged in a structure that is attached to theinner body frame. The cage is configured so as to provide the nut with arange of movement so that when a component is coupled to the frame, thealignment of the component and frame can be adjusted until they meetmanufacturing standards. Unfortunately, mating surfaces are not alwaysperpendicular.

Prior to final coupling of the components to the non-perpendicularsurfaces of the frame, however, the fastener must be aligned to reducethe incidence of cross-threading of the fastener. To date, the step ofrotating a fastener into the nut will often cause the fastener tocross-thread. This causes a significant amount of rework of the fastenerjoint and, therefore, causes manufacturing problems in the finalassembly of the product. To prevent the manufacturing problems,post-process rework is often required to ensure that the fasteners canbe properly coupled with an appropriate strength.

SUMMARY OF THE INVENTION

Accordingly, this invention provides a cage nut fastener which isweldable to a substructure that overcomes the problems and disadvantagesof the cage nuts of the prior art. Briefly, the invention includes afastener having a threaded head, a fastener cage capable of fasteningthe fastener to a substructure, the cage being formed having a topbearing surface which is angled with respect to a base bearing surface.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The greatest advantage of the present invention will become apparent toone skilled in the art upon reading the following specification and byreference to the drawings in which:

FIG. 1 is a perspective view of the cage nut fastener in its assembledcondition;

FIG. 2 is a perspective view of the nut and base plate of the presentinvention;

FIG. 3 is a perspective view of the cage in FIG. 1;

FIGS. 4 a-4 d represent top, side, and end views of the cage nutfastener shown in FIG. 3;

FIG. 5 represents a cross sectional perspective view of the cage nutshown in FIG. 1;

FIG. 6 represents the use of the cage nut shown in FIG. 1;

FIG. 7 a-4 c represent top, side, and end views of an alternate cage;

FIG. 8 represents an unfolded view of the cage shown in FIG. 7 a;

FIG. 9 is a perspective view of an alternate cage nut fastener in itsassembled condition;

FIGS. 10 a and 10 b represent a perspective view of the nut and baseplate of the present invention;

FIGS. 11 a-11 c represent top, side, and end views of the cage shown inFIG. 9; and

FIGS. 12 a and 12 b represent side views of the caged fastener shown inFIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

With reference to FIGS. 1-3, a cage nut fastener, shown generally at 8,has a body 16 coupled to a planar base 12. The body 16 and planar base12 define a threaded through bore 14. Planar base 12 has an upper basesurface 18 and lower base surface 20. The cage nut assembly 8 furtherhas a cage 22 which is generally disposed about the planar base 12. Thecage 22 has a cage upper surface 34 and cage lower surface 32. The cage22 upper surface 34 is defined by a pair of co-planar flanges 28. Theupper surface 34 defines a through hole 26 which generally correspondsto the shape of the body 16.

As best seen in FIG. 2, the body 16 takes the form of a cylinder 35coupled to the planar base 12. The planar base 12 defines a hole whichis co-axial to the threaded through bore 14 of the cylinder 35. It ispreferred that the cylinder 35 be of a hot or cold formed body ofsuitable size defined by the needed configuration. Also, it is preferredthat the cylinder 35 be of sufficient hardness through either heattreatment or metallurgy to ensure the proper coupling to the mating bolt(not shown).

As seen in FIG. 2, each corner 40 a-d of the planar base 12 has definedradii 42 a-c which function as a load bearing surfaces to applydistributed loads to an interior surface 44 a and 44 b of the dependingsidewalls 46 a and 46 b of the cage 22 when a bolt is inserted. The cage22 is formed of a single folded piece of sheet metal 48. The cage 22 hasa through hole 50 which has a diameter larger than the diameter of thecylinder 35. The side 52 of the hole 50 limits the travel of thecylinder 35 within the cage 22.

The pair of depending sidewalls 46 a and 46 b of the cage 22 functionsto couple the top members 54 a and 54 b of the cage 22 to the weldablelower members 56. Additionally, the depending sidewalls 46 a and 46 babsorb torsional energy imparted onto the cage 22 by the corners 40 a-dof the base 12. The height of the cage 22 minimizes the movement of thebase 12 away from the lower member 56 and further allows the cylinder 35to rotate to ensure proper alignment upon driving of the couplingthreaded fastener (not shown).

As seen in FIG. 4 a, member 56 defines a through hole 58 which isco-axial to the passage of the cylindrical body 35 and the planar base12. Additionally formed on the interior surface 62 defining the lowermember 56 is a number of optional upturned tabs (not shown) which raisethe base 12 above the lower members 56 to prevent adhesion duringpainting applications. Additionally defined on the lower member 56 isfour weldment pad areas 66 a-d which provide the area to allow weldingof the cage 22 to the base substrate material.

As best seen in FIGS. 4 a-4 c and 5, the sidewalls 44 a and 44 b havevarying lengths. In this regard, the first sidewall 46 a has a firstlength shorter than the sidewall 46 b. Additionally, the top members 54a and 54 b are co-planar as to the affixed angle (θ) from the surfacedefined by the lower member 32. This forms a pair of internal bearingsurfaces 68 a and 68 b which are configured to interface with the upperbase surface 18 of the planar base 12. As shown in FIGS. 4 d and 5, theangled internal bearing surfaces 68 a and 68 b allow for the relativerotation of the body 16 with respect to the cage 12 at the defined angle(θ). The through bore 26 is sized so as to allow the rotation of thebase 12 and cylindrical body 16.

As shown in FIG. 6, the caged fastener 8 is welded onto a body 70 havingan angled surface 72. As seen, the angle (θ) of the internal bearingsurfaces 68 a and 68 b are configured to be perpendicular to the bolt74. The body 70 optionally has a defined through slot 76 which allowsthe bolt 74 to be inserted at a first angle. Upon tightening of the bolt74, the lower surface 20 of the planar base 12 interfaces with the lowermember 56 to allow rotation of the bolt 44 within the slot 76.

FIGS. 7 a-7 c represent an alternate configuration for the cage 22. Asshown, the upper members 54 a and 54 b can take any suitableconfiguration which allows them to encase the body and base 12.Furthermore, the upper members 54 a and 54 b are configured torotationally align the threaded bore 14 with a bolt which is insertedthrough the hole 58 at an angle which is non-perpendicular to the lowermember 56.

FIG. 8 represents a perspective view of the unfolded cage. The cage 22is formed by folding the generally rectangular form into a box section.Defined on the exterior edge of the unfolded cage is a pair ofsemi-circular cutouts 78 and 80 which define the aperture 26 once thecage 22 has been folded. Further defined is a cutout portion 82 which isused to locate and index the part upon welding to the body 70.

With reference to FIGS. 9-11 c, an alternate cage nut fastener, showngenerally at 8′, has a hexagonal body 16 coupled to a planar base 12.The body 16 and planar base 12 define a threaded through bore 14. Planarbase 12 has an upper base surface 18 and lower base surface 20. The cagenut assembly 8 further has a cage 22 which is generally disposed aboutthe planar base 12. The cage 22 has a cage upper surface 34 and cagelower surface 32. The cage 22 lower surface is defined by a pair ofco-planar flanges 28. The upper surface 34 defines a through hole 26which generally corresponds to the shape of the hexagonal body 16.

As best seen in FIG. 10 a, the hexagonal body 16 takes the form of a hexnut 38 coupled to the planar base 12. The planar base 12 defines a hole36 which is co-axial to the threaded through bore 14 of the hex nut 38.It is preferred that the hex nut 38 be of a type 10 hex nut or othersuitable size defined by the needed configuration. Also, it is preferredthat the hex nut 38 be of sufficient hardness through either heattreatment or metallurgy to ensure the proper coupling to the mating bolt(not shown). As described above, the sidewalls 46 a and 46 b vary inlength so as to allow the rotation of the fastener within the cage 22.

As seen in FIG. 10 a, each corner 40 a-d of the planar base 12 hasdefined flats 42 a-d which function as load bearing surfaces to applydistributed loads to an interior surface 44 a and 44 b of the dependingsidewalls 46 a and 46 b of the cage 22 when a bolt is inserted.

As best seen in FIGS. 11 a-11 c, the cage 22 is formed of a singlefolded piece of sheet metal 48. The cage 22 has a through hole 50 whichhas a diameter larger than the diameter of the hex nut 38. The side 52of the hole 50 limits the travel of the hex nut 38 within the cage 22.

The pair of depending sidewalls 46 a and 46 b of the cage 22 functionsto couple the top member 54 of the cage 22 to the weldable lower members56. Additionally, the depending sidewalls 46 a and 46 b absorb torsionalenergy imparted onto the cage 22 by the corners 40 a-d of the base 12.The height of the cage 22 minimizes the movement of the base 12 awayfrom the lower members 56 and further allows the hex nut 38 to rotate toensure proper alignment upon driving of the coupling threaded fastener(not shown).

As seen in FIGS. 12 a and 12 b, the lower members 56 define a throughhole 58 which is co-axial to the passage of the hex nut 38 and theplanar base 12. Additionally formed on the two sides 60 and 62 definingthe lower members 56 are a number of upturned tabs 64 which raise thebase 12 above the lower members 56 to prevent adhesion during paintingapplications. Additionally defined on the lower members 56 are fourweldment pad areas 66 a-d which provide the area to allow for welding ofthe cage to the base substrate material. Defined generally equidistantbetween the two sides 60 and 62 is a seam, formed when the cage iswrapped around the base 12.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

1. A cage nut for welding to a mounting surface comprising: a fastenerhaving a body coupled to a base having a bearing surface; and a cageadapted to enclose a portion of the fastener, said cage having first andsecond depending sidewalls which function to couple a cage top member toa pair of co-planar flanges, said pair of co-planar flanges beingpartially disposed between the bearing surface and the mounting surface,each of said flanges having first and second portions, said first andsecond portion being adapted to be welded to the mounting surface andwherein said flanges further define a seam disposed between said bodyand said surface, and wherein said first depending wall has a firstheight less than a second height of the second depending sidewall. 2.The cage nut assembly in accordance with claim 1, wherein the base isplanar.
 3. The cage nut assembly in accordance with claim 1, wherein thebody has at least six surfaces and is coupled to a planar base, the bodyand planar base define a threaded through bore.
 4. The cage nut assemblyin accordance with claim 3, wherein the cage defines a through holewhich generally co-axial with the through bore.
 5. The cage nut assemblyin accordance with claim 1, wherein the cage defines a pair of co-planarwelding flanges.
 6. The cage nut assembly in accordance with claim 1,wherein the cage top member is formed of a single piece.
 7. A floatingfastener comprising: a body coupled to a base; and a cage adapted toenclose the base and being adapted to be welded to a surface, said cagehaving a pair of flanges partially disposed adjacent the bearingsurface, each of said flanges having first and second portions, saidfirst and second portion being adapted to be welded to a surface andwherein said flanges further define a seam disposed between said bodyand said surface, wherein the cage has first and second dependingsidewalls which function to couple a cage top member to the flanges,said first depending sidewall having a first height less than the heightof the second depending sidewall.
 8. The floating fastener assembly inaccordance with claim 7, wherein the base is planar and wherein the cagedefines a pair of flanges which cover at least a portion of the base. 9.The floating fastener assembly in accordance with claim 7, wherein thehexagonal body and planar base define a threaded through bore.
 10. Thefloating fastener assembly in accordance with claim 7, wherein the cagedefines a through hole which has a diameter larger than a diameter ofthe body.
 11. The floating fastener assembly in accordance with claim 7,wherein the cage member defines a top surface which is non-parallel tothe flanges.
 12. The floating fastener assembly in accordance with claim7, wherein the base defines a plurality of corners, each corner definingflats which are configured to function as a load bearing surfaces toapply and distributed loads to an interior surface of the dependingsidewalls of the cage.
 13. A floating fastener adapted to be welded to asurface comprising: a body coupled to a planar base having definedbearing surfaces; and a cage adapted to enclose the body, wherein thecage has first and second depending sidewalls which function to couple acage top member to a plurality of flanges partially disposed adjacentthe bearing surface, each of said flanges having first and secondportions, said first and second portion being adapted to be welded to asurface and wherein said flanges further define a seam disposed betweensaid body and the surface, wherein the bearing surfaces distribute loadsto the first and second depending sidewalls.
 14. The floating fastenerassembly in accordance with claim 13, wherein the seam is disposedgenerally equidistant between the first and second depending sidewalls.15. The floating fastener assembly in accordance with claim 13, whereinthe flanges are configured to allow welding of the cage to the surfacesuch that the seam is disposed between at least first and secondportion.
 16. The floating fastener assembly in accordance with claim 13,wherein the flanges define a number of upturned tabs which areconfigured to raise the base above the flanges to prevent adhesionduring painting applications.
 17. The floating fastener assembly inaccordance with claim 13, wherein the cage is wrapped around the planarbase.
 18. The floating fastener assembly in accordance with claim 13,wherein the cage top member defines a through hole which has a diameterlarger than a diameter of the body.
 19. The floating fastener assemblyin accordance with claim 13, wherein the planar base defines a holewhich is co-axial to a threaded bore defined by the body.
 20. Thefloating fastener assembly in accordance with claim 13, wherein theflanges define an aperture which is co-axial to a threaded bore definedby the body and wherein the seam is defined through the aperture.
 21. Afastener assembly adapted to be coupled to a surface comprising: athreaded fastener comprising a body having defined flats; a cage adaptedto enclose the fastener, the cage having a pair of flanges disposedadjacent to the body, said flanges defining a seam and a plurality ofweldment locations, wherein the weldment locations are configured to bewelded to the surface and to prevent the opening of the seam uponapplication of a torque to the fastener, wherein the defined flatsdistribute loads to surfaces of the cage, said cage defines a firstdepending side wall having a first height and a second depending sidewall having a second height smaller than the first height, said cagefurther having a top member with a surface that is angled with respectto the flanges.
 22. The fastener assembly according to claim 21 whereinthe seam is disposed between the threaded fastener and the surface. 23.The fastener assembly according to claim 21 wherein the threadedfastener comprises a planar base and the cage comprises a bearingsurface configured to interface with the base.
 24. The fastener assemblyaccording to claim 21 wherein the weldment locations are positionedgenerally adjacent to the seam.
 25. The fastener assembly according toclaim 21 wherein a first weldment location is positioned on a first sideof the seam and a second weldment location is located on a second sideof the seam.
 26. A cage nut comprising: a fastener having a body coupledto a base; and a cage adapted to enclose a portion of the fastener, saidcage defines a seam disposed between said body and said surface, andsaid cage further defines first and second flanges wherein said firstflange being disposed on a first side of said seam and said secondflange is disposed on a second side of the seam said first and secondflanges each having first and second weldment areas configured to bewelded to a surface, said cage having an angled top member coupled tothe first and second flanges by a pair of depending sidewalls havingdiffering heights.
 27. A floating fastener comprising: a body coupled toa base; and a cage adapted to enclose the base and being adapted to bewelded to a surface, wherein the cage has a pair of depending sidewalls,each depending sidewall having a different height, and which function tocouple a cage top member to a pair of weldable lower members, saidweldable lower members define a seam disposed between said body and saidsurface and wherein the weldable lower members define a plurality oftabs disposed on either side of said seam.